Interlock and surgical instrument including same

ABSTRACT

A robotic surgical system comprising a surgical robot, a surgical instrument, a motor, and a current sensor is disclosed. The surgical instrument comprises an end effector, a firing assembly, and a lockout mechanism. The firing assembly comprises a firing member movable from an unfired position to a fired position during a firing stroke and a sled movable from a proximal position to a distal position. The lockout mechanism is configured to prevent the firing stroke when the sled is not in the proximal position. The motor is operably coupled with the firing member and couplable with a supply of current. When the current through the motor exceeds a threshold value the firing member is prevented from completing the firing stroke. The threshold value corresponds to the current through the motor when the lockout mechanism is activated. The motor is de-energized when the current through the motor exceeds the threshold value.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming priority under35 U.S.C. § 120 to U.S. patent application Ser. No. 14/303,049, entitledINTERLOCK AND SURGICAL INSTRUMENT INCLUDING SAME, filed Jun. 12, 2014,which issued on Oct. 8, 2019 as U.S. Pat. No. 10,433,918, which is acontinuation application claiming priority under 35 U.S.C. § 120 to U.S.patent application Ser. No. 14/176,671, entitled SURGICAL INSTRUMENTWITH WIRELESS COMMUNICATION BETWEEN A CONTROL UNIT OF A ROBOTIC SYSTEMAND REMOTE SENSOR, filed Feb. 10, 2014, which issued on Oct. 15, 2019 asU.S. Pat. No. 10,441,369, which is a continuation application claimingpriority under 35 U.S.C. § 120 to U.S. patent application Ser. No.13/118,259, entitled SURGICAL INSTRUMENT WITH WIRELESS COMMUNICATIONBETWEEN A CONTROL UNIT OF A ROBOTIC SYSTEM AND REMOTE SENSOR, filed May27, 2011, which issued on Apr. 1, 2014 as U.S. Pat. No. 8,684,253, whichis a continuation-in-part application claiming priority under 35 U.S.C.§ 120 to U.S. patent application Ser. No. 11/651,807, entitled SURGICALINSTRUMENT WITH WIRELESS COMMUNICATION BETWEEN CONTROL UNIT AND REMOTESENSOR, filed Jan. 10, 2007, which issued on Jun. 11, 2013 as U.S. Pat.No. 8,459,520, the entire disclosures of which are hereby incorporatedby reference herein.

COMMONLY-OWNED PATENT APPLICATIONS

The Assignee of the subject application also co-owns the following U.S.Patent Applications which are herein incorporated by reference in theirentireties:

(1) U.S. patent application Ser. No. 11/651,715, filed Jan. 10, 2007,now U.S. Pat. No. 8,652,120, entitled SURGICAL INSTRUMENT WITH WIRELESSCOMMUNICATION BETWEEN CONTROL UNIT AND SENSOR TRANSPONDERS;

(2) U.S. patent application Ser. No. 11/651,806, filed Jan. 10, 2007,now U.S. Pat. No. 7,954,682, entitled SURGICAL INSTRUMENT WITH ELEMENTSTO COMMUNICATE BETWEEN CONTROL UNIT AND END EFFECTOR;

(3) U.S. patent application Ser. No. 11/651,768, filed Jan. 10, 2007,now U.S. Pat. No. 7,721,931, entitled PREVENTION OF CARTRIDGE REUSE IN ASURGICAL INSTRUMENT;

(4) U.S. patent application Ser. No. 11/651,771, filed Jan. 10, 2007,now U.S. Pat. No. 7,738,971, entitled POST-STERILIZATION PROGRAMMING OFSURGICAL INSTRUMENTS;

(5) U.S. patent application Ser. No. 11/651,788, filed Jan. 10, 2007,now U.S. Pat. No. 7,721,936, entitled INTERLOCK AND SURGICAL INSTRUMENTINCLUDING SAME; and

(6) U.S. patent application Ser. No. 11/651,785, filed Jan. 10, 2007,now U.S. Pat. No. 7,900,805, entitled SURGICAL INSTRUMENT WITH ENHANCEDBATTERY PERFORMANCE.

FIELD OF THE INVENTION

The disclosed invention relates generally and in various embodiments tosurgical stapling and cutting instruments structured and configured forapplying lines of staples from a staple cartridge into tissue whilecutting the tissue between the applied staple lines. More particularlythe disclosed invention relates to an interlock for use in motorizedsurgical stapling and cutting instruments that prevents cutting of thetissue when the staple cartridge is not installed, or when the staplecartridge is installed but spent.

BACKGROUND

Endoscopic surgical instruments are often preferred over traditionalopen surgical devices since a smaller incision tends to reducepost-operative recovery time and complications. Consequently,significant development has gone into a range of endoscopic surgicalinstruments that are suitable for precise placement of a distal endeffector at a desired surgical site through a cannula of a trocar. Thesedistal end effectors engage the tissue in a number of ways to achieve adiagnostic or therapeutic effect (e.g., endocutter, grasper, cutter,staplers, clip applier, access device, drug/gene therapy deliverydevice, and energy device using ultrasound, RF, laser, etc.).

Known surgical staplers include an end effector that simultaneouslymakes a longitudinal incision in tissue and applies lines of staples onopposing sides of the incision. The end effector includes a pair ofcooperating jaw members that, if the instrument is intended forendoscopic or laparoscopic applications, are capable of passing througha cannula passageway. One of the jaw members receives a staple cartridgehaving at least two laterally spaced rows of staples. The other jawmember defines an anvil having staple-forming pockets aligned with therows of staples in the cartridge. The instrument includes a plurality ofreciprocating wedges which, when driven distally, pass through openingsin the staple cartridge and engage drivers supporting the staples toeffect the firing of the staples toward the anvil.

Advantageously, the design of the end effector may be such that it canbe reused with the surgical stapler. For instance, one patient may needa series of severing and stapling operations. Replacing an entire endeffector for each operation tends to be economically inefficient,especially if the end effector is built for strength and reliabilityover repeated operations. To that end, the staple cartridge is typicallyconfigured to be disposable and is fitted into the end effector prior toeach operation of the surgical stapler.

An example of a surgical stapler suitable for endoscopic applications isdescribed in U.S. Pat. No. 5,465,895, entitled SURGICAL STAPLERINSTRUMENT, which issued on Nov. 14, 1995, which discloses an endocutterwith distinct closing and firing actions. Thereby, an operator is ableto close the jaw members upon tissue to position the tissue prior tofiring. Once the operator has determined that the jaw members areproperly gripping tissue, the operator can then fire the surgicalstapler with either a single firing stroke or multiple firing strokes,depending on the device. Firing the surgical stapler causes severing andstapling of the tissue. The simultaneous severing and stapling avoidscomplications that may arise when performing such actions sequentiallywith different surgical tools that respectively only sever and staple.

One specific advantage of being able to close upon tissue before firingis that the operator is able to verify via an endoscope that the desiredlocation for the cut has been achieved, including a sufficient amount oftissue has been captured between opposing jaws. Otherwise, opposing jawsmay be drawn too close together, especially pinching at their distalends, and thus not effectively forming closed staples in the severedtissue. At the other extreme, an excessive amount of clamped tissue maycause binding and an incomplete firing.

Because the actuating force (i.e., the “force-to-fire”, or FTF)necessary to close the jaws and simultaneously perform the cutting andstapling operation may be considerable, a manually-powered cutting andstapling instrument such as that described above may not be utilizableby otherwise qualified operators who are unable to generate the requiredFTF. Accordingly, powered cutting and stapling instruments have beendeveloped for decreasing the force-to-fire (FTF). Such instrumentstypically incorporate motors or other actuating mechanisms suitable forsupplementing or replacing operator-generated force for performing thecutting and stapling operation.

Although powered instruments provide numerous advantages, it isdesirable to prevent inadvertent firing of the instrument under certainconditions. For example, firing the instrument without having a staplecartridge installed, or firing the instrument having an installed butspent (e.g., previously fired) staple cartridge, may result in cuttingof tissue without simultaneous stapling to minimize bleeding. Interlocksfor preventing powered endocutter operation under such conditions haveheretofore utilized electronic sensors in the end effector fordetermining whether an unspent staple cartridge has been installed inthe end effector. U.S. patent application Ser. No. 11/343,439 entitledELECTRONIC INTERLOCKS AND SURGICAL INSTRUMENT INCLUDING SAME, now U.S.Pat. No. 7,644,848, which issued on Jan. 12, 2010, the disclosure ofwhich is incorporated herein by reference, discloses the use ofelectronic sensors disposed within the end effector for determining ifan unspent staple cartridge has been installed. The sensors may includeswitches connected in series with a motor or other electrically-poweredactuation mechanism such that current flow necessary for generating theactuating force is prevented when the staple cartridge is not installed,or when the staple cartridge is installed but spent. Although suchelectronic interlocks are effective, placement of sensors in the endeffector and routing electrical cabling between the sensors and motorelectronics (typically housed in the instrument handle) increasesinstrument complexity and cost.

Although the use of mechanical interlocks in end effectors forpreventing inadvertent firing is known and avoids complexitiesassociated with end effector electronics, such mechanisms haveheretofore been limited to manually powered endocutters. In particular,such mechanisms may not have the mechanical strength to resist thefiring force generated by electrically-powered actuation mechanisms.Additionally, even if a mechanical interlock is capable of withstandingthe firing force, the resulting physical stresses may be transmitted toother instrument components and cause unacceptable wear or damage.

Consequently, a significant need exists for an interlock for use inpowered cutting and stapling instruments that prevents inadvertentfiring (e.g., cutting but not stapling) while avoiding complexities ofsensor-equipped end effectors and deleterious physical stresses that mayotherwise result from the use of conventional mechanical interlocks.

SUMMARY

This application discloses a surgical cutting and stapling instrumentaccording to various embodiments. The instrument includes an endeffector comprising a moveable cutting instrument to cut an object and amotor to actuate the cutting instrument in response to a currenttherethrough. The actuation of the cutting instrument causes the cuttinginstrument to move between a proximal-most position and a distal-mostposition. The instrument further includes an interlock coupled to theend effector and to the motor to prevent actuation of the cuttinginstrument based on the current through the motor.

This application further discloses a method for preventing operation ofa surgical instrument. The surgical instrument is configured forremovably receiving an expendable staple cartridge and comprises amoveable cutting instrument and a motor to actuate the cuttinginstrument in response to a current therethrough. The method comprisesmechanically blocking actuation of the cutting instrument by the motorin the absence of an unexpended staple cartridge in the instrument,detecting the current through the motor resulting from the blockedactuation of the cutting instrument, and interrupting the currentthrough the motor based on the detected current.

In various embodiments, a robotic surgical system comprising a surgicalrobot, a surgical instrument, a motor, and a current sensor isdisclosed. The surgical instrument comprises an end effector, a firingassembly, and a lockout mechanism. The end effector comprises an anvil,a channel, and a cartridge configured to be replaceably positioned inthe channel. The firing assembly comprises a firing member movable froman unfired position to a fired position during a firing stroke and asled movable from a proximal position to a distal position as the firingmember is moved through the firing stroke. The lockout mechanism isconfigured to prevent the firing stroke when the sled is not in theproximal position. The motor comprises a rotatable output. The rotatableoutput is operably coupled with the firing member. The motor iscouplable with a supply of current. The current sensor is configured todetect the current through the motor. When the current through the motorexceeds a threshold value the firing member is prevented from completingthe firing stroke. The threshold value corresponds to the currentthrough the motor when the lockout mechanism is activated. The motor isde-energized when the current through the motor exceeds the thresholdvalue.

In various embodiments, a robotic surgical system comprising a surgicalinstrument, a motor, and a sensing system is disclosed. The surgicalinstrument comprises an end effector, a firing assembly, a lockoutmechanism. The end effector comprises an anvil jaw, a staple cartridgejaw comprising a channel, and a staple cartridge configured to bereleasably positioned within the channel. The firing assembly comprisesa firing member movable from an unfired position to a fired positionduring a firing stroke and a sled movable from a proximal position to adistal position. The lockout mechanism is configured to prevent thefiring stroke when the sled is not in the proximal position. The motorcomprises a rotatable output. The rotatable output is operably coupledwith the firing member. The rotatable output is configured to move thefiring member between the unfired position and the fired position. Themotor is couplable with a supply of current. The sensing system isconfigured to detect the current through the motor. The firing member isprevented from continuing the firing stroke when the current through themotor exceeds a threshold value. The current through the motor exceedingthe threshold value is indicative of the lockout mechanism beingactivated. The motor is de-energized when the current through the motorexceeds the threshold value.

In various embodiments, a robotic surgical system comprising a surgicalrobot, a surgical instrument, a motor, and a lockout circuit isdisclosed. The surgical instrument comprises an end effector, a firingassembly, and a lockout mechanism. The end effector comprises alongitudinally extending channel, an anvil pivotally attached to thechannel, and a staple cartridge replaceably positioned in the channel.The firing assembly comprises a firing member movable from an unfiredposition to a fired position during a firing stroke and a sled movablefrom a proximal position to a distal position as the firing member ismoved through the firing stroke. The lockout mechanism is configured toprevent the firing stroke when the sled is not in the proximal position.The motor comprises a rotatable output. The rotatable output is operablycoupled with the firing member. The motor is configured to be coupledwith a supply of current. The lockout circuit is configured to sense thecurrent through the motor and prevent the completion of the firingstroke when the current through the motor exceeds a threshold value. Thethreshold value corresponds to the current through the motor when thesled is not in the proximal position. The motor is de-energized when thecurrent through the motor exceeds the threshold value.

BRIEF DESCRIPTION OF THE FIGURES

Various embodiments of the present invention are described herein by wayof example in conjunction with the following figures, wherein:

FIGS. 1 and 2 are perspective views of a surgical cutting and fasteninginstrument according to various embodiments of the present invention;

FIG. 3A is an exploded view of the end effector according to variousembodiments of the present invention;

FIG. 3B is a perspective view of the cutting instrument of FIG. 3A;

FIGS. 4 and 5 are exploded views of an end effector and shaft of theinstrument according to various embodiments of the present invention;

FIG. 6 is a side view of the end effector according to variousembodiments of the present invention;

FIG. 7 is an exploded view of the handle of the instrument according tovarious embodiments of the present invention;

FIGS. 8 and 9 are partial perspective views of the handle according tovarious embodiments of the present invention;

FIG. 10 is a side view of the handle according to various embodiments ofthe present invention;

FIGS. 11-12 illustrate a proportional sensor that may be used accordingto various embodiments of the present invention;

FIGS. 13-27 illustrate mechanical blocking mechanisms and the sequentialoperation of each according to various embodiments of the presentinvention;

FIGS. 28-29 illustrate schematic diagrams of circuits used in theinstrument according to various embodiments of the present invention;

FIG. 30 is a flow diagram of a process implemented by themicrocontroller of FIG. 29 according to various embodiments of thepresent invention; and

FIG. 31 is a flow diagram of a process implemented by an interlockaccording to various embodiments of the present invention.

DETAILED DESCRIPTION

FIGS. 1 and 2 depict a surgical cutting and fastening instrument 10according to various embodiments of the present invention. Theillustrated embodiment is an endoscopic instrument and, in general, theembodiments of the instrument 10 described herein are endoscopicsurgical cutting and fastening instruments. It should be noted, however,that according to other embodiments of the present invention, theinstrument may be a non-endoscopic surgical cutting and fasteninginstrument, such as a laparoscopic instrument.

The surgical instrument 10 depicted in FIGS. 1 and 2 comprises a handle12, a shaft 14, and an articulating end effector 16 pivotally connectedto the shaft 14 at an articulation pivot 18. An articulation control 20may be provided adjacent to the handle 12 to effect rotation of the endeffector 16 about the articulation pivot 18. In the illustratedembodiment, the end effector 16 is configured to act as an endocutterfor clamping, severing and stapling tissue, although, in otherembodiments, different types of end effectors may be used, such as endeffectors for other types of surgical devices, such as graspers,cutters, staplers, clip appliers, access devices, drug/gene therapydevices, ultrasound, RF or laser devices, etc.

The handle 12 of the instrument 10 may include a closure trigger 22 anda firing trigger 24 for actuating the end effector 16. It will beappreciated that instruments having end effectors directed to differentsurgical tasks may have different numbers or types of triggers or othersuitable controls for operating the end effector 16. The end effector 16is shown separated from the handle 12 by a preferably elongate shaft 14.In one embodiment, a operator of the instrument 10 may articulate theend effector 16 relative to the shaft 14 by utilizing the articulationcontrol 20 as described in more detail in pending U.S. patentapplication Ser. No. 11/329,020 entitled SURGICAL INSTRUMENT HAVING ANARTICULATING END EFFECTOR, now U.S. Pat. No. 7,670,334, which issued onMar. 2, 2010, which is incorporated herein by reference.

The end effector 16 includes in this example, among other things, astaple channel 26 and a pivotally translatable clamping member, such asan anvil 28, which are maintained at a spacing that assures effectivestapling and severing of tissue clamped in the end effector 16. Thehandle 12 includes a pistol grip 30 towards which a closure trigger 22is pivotally drawn by the operator to cause clamping or closing of theanvil 28 toward the staple channel 26 of the end effector 16 to therebyclamp tissue positioned between the anvil 28 and the channel 26. Thefiring trigger 24 is farther outboard of the closure trigger 22. Oncethe closure trigger 22 is locked in the closure position as furtherdescribed below, the firing trigger 24 may rotate slightly toward thepistol grip 30 so that it can be reached by the operator using one hand.The operator may then pivotally draw the firing trigger 24 toward thepistol grip 30 to cause the stapling and severing of clamped tissue inthe end effector 16. In other embodiments, different types of clampingmembers besides the anvil 28 may be used, such as, for example, anopposing jaw, etc.

It will be appreciated that the terms “proximal” and “distal” are usedherein with reference to a operator gripping the handle 12 of aninstrument 10. Thus, the end effector 16 is distal with respect to themore proximal handle 12. It will be further appreciated that, forconvenience and clarity, spatial terms such as “vertical” and“horizontal” are used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and absolute.

The closure trigger 22 may be actuated first. Once the operator issatisfied with the positioning of the end effector 16, the operator maydraw back the closure trigger 22 to its fully closed, locked positionproximate to the pistol grip 30. The firing trigger 24 may then beactuated. The firing trigger 24 returns to the open position (shown inFIGS. 1 and 2) when the operator removes pressure, as described morefully below. A release button 32 on the handle 12, when depressed, mayrelease the locked closure trigger 22. Various configurations forlocking and unlocking the closure trigger 22 using the release button 32are described in pending U.S. patent application Ser. No. 11/343,573entitled MOTOR-DRIVEN SURGICAL CUTTING AND FASTENING INSTRUMENT WITHLOADING FORCE FEEDBACK, now U.S. Pat. No. 7,416,101, which issued onAug. 26, 2008, which is incorporated herein by reference.

FIG. 3A is an exploded view of the end effector 16 according to variousembodiments. As shown in the illustrated embodiment, the end effector 16may include, in addition to the previously-mentioned channel 26 andanvil 28, a cutting instrument 34, a sled 36, a staple cartridge 38 thatis removably seated (e.g., installed) in the channel 26, and a helicalscrew shaft 40, and FIG. 3B is a perspective view of the cuttinginstrument of FIG. 3A.

The anvil 28 may be pivotably opened and closed at a pivot point 42connected to the proximate end of the channel 26. The anvil 28 may alsoinclude a tab 44 at its proximate end that is inserted into a componentof the mechanical closure system (described further below) to open andclose the anvil 28. When the closure trigger 22 is actuated, that is,drawn in by an operator of the instrument 10, the anvil 28 may pivotabout the pivot point 42 into the clamped or closed position. Ifclamping of the end effector 16 is satisfactory, the operator mayactuate the firing trigger 24, which, as explained in more detail below,causes the cutting instrument 34 to travel longitudinally along thechannel 26.

As shown, the cutting instrument 34 includes upper guide pins 46 thatenter an anvil slot 48 in the anvil 28 to verify and assist inmaintaining the anvil 28 in a closed state during staple formation andsevering. Spacing between the channel 26 and anvil 28 is furthermaintained by the cutting instrument 34 by having middle pins 50 slidealong the top surface of the channel 26 while a bottom foot 52opposingly slides along the undersurface of the channel 26, guided by alongitudinal opening 54 in the channel 26. A distally presented cuttingsurface 56 between the upper guide pins 46 and middle pins 50 seversclamped tissue while distally-presented surface 58 actuates the staplecartridge 38 by progressively driving the sled 36 from an unfiredposition to a fired position. Actuation of the staple cartridge 38causes staple drivers 60 to cam upwardly, driving staples 62 out ofupwardly open staple holes 64 formed in the staple cartridge 38. Thestaples 62 are subsequently formed against a staple forming undersurface66 of the anvil 28. A staple cartridge tray 68 encompasses from thebottom the other components of the staple cartridge 38 to hold them inplace. The staple cartridge tray 68 includes a rearwardly open slot 70that overlies the longitudinal opening 54 in the channel 26. A lowersurface of the staple cartridge 38 and an upward surface of the channel26 form a firing drive slot 200 (FIG. 6) through which the middle pins50 pass during distal and proximal movement of the cutting instrument34. The sled 36 may be an integral component of the staple cartridge 38such that when the cutting instrument 34 retracts following the cuttingoperation, the sled 36 does not retract. U.S. Pat. No. 6,978,921entitled SURGICAL STAPLING INSTRUMENT INCORPORATING AN E-BEAM FIRINGMECHANISM, which issued on Dec. 27, 2005, which is incorporated hereinby reference, provides more details about such two-stroke cutting andfastening instruments.

It should be noted that although the embodiments of the instrument 10described herein employ an end effector 16 that staples the severedtissue, in other embodiments different techniques for fastening orsealing the severed tissue may be used. For example, end effectors thatuse RF energy or adhesives to fasten the severed tissue may also beused. U.S. Pat. No. 5,709,680 entitled ELECTROSURGICAL HEMOSTATICDEVICE, which issued on Jan. 20, 1998, and U.S. Pat. No. 5,688,270entitled ELECTROSURGICAL HEMOSTATIC DEVICE WITH RECESSED AND/OR OFFSETELECTRODES, which issued on Nov. 18, 1997, both of which areincorporated herein by reference, disclose cutting instruments that usesRF energy to fasten the severed tissue. U.S. patent application Ser. No.11/267,811 entitled SURGICAL STAPLING INSTRUMENTS STRUCTURED FORDELIVERY OF MEDICAL AGENTS, now U.S. Pat. No. 7,673,783, which issued onMar. 9, 2010, and U.S. patent application Ser. No. 11/267,383 entitledSURGICAL STAPLING INSTRUMENTS STRUCTURED FOR PUMP-ASSISTED DELIVERY OFMEDICAL AGENTS, now U.S. Pat. No. 7,607,557, which issued on Oct. 27,2009, both of which are also incorporated herein by reference, disclosecutting instruments that uses adhesives to fasten the severed tissue.Accordingly, although the description herein refers to cutting/staplingoperations and the like, it should be recognized that this is anexemplary embodiment and is not meant to be limiting. Othertissue-fastening techniques may also be used.

FIGS. 4 and 5 are exploded views and FIG. 6 is a side view of the endeffector 16 and shaft 14 according to various embodiments. As shown inthe illustrated embodiment, the shaft 14 may include a proximate closuretube 72 and a distal closure tube 74 pivotably linked by a pivot links76. The distal closure tube 74 includes an opening 78 into which the tab44 on the anvil 28 is inserted in order to open and close the anvil 28,as further described below. Disposed inside the closure tubes 72, 74 maybe a proximate spine tube 79. Disposed inside the proximate spine tube79 may be a main rotational (or proximate) drive shaft 80 thatcommunicates with a secondary (or distal) drive shaft 82 via a bevelgear assembly 84. The secondary drive shaft 82 is connected to a drivegear 86 that engages a proximate drive gear 88 of the helical screwshaft 40. The vertical bevel gear 84 b may sit and pivot in an opening90 in the distal end of the proximate spine tube 79. A distal spine tube92 may be used to enclose the secondary drive shaft 82 and the drivegears 86, 88. Collectively, the main drive shaft 80, the secondary driveshaft 82, and the articulation assembly (e.g., the bevel gear assembly84 a-c) are sometimes referred to herein as the “main drive shaftassembly.”

A bearing 94 (FIG. 6) positioned at a distal end of the staple channel26 receives the helical screw shaft 40, allowing the helical screw shaft40 to freely rotate with respect to the channel 26. The helical screwshaft 40 may interface a threaded opening (not shown) of the cuttinginstrument 34 such that rotation of the helical screw shaft 40 causesthe cutting instrument 34 to translate distally or proximately(depending on the direction of the rotation) through the staple channel26. Accordingly, when the main drive shaft 80 is caused to rotate byactuation of the firing trigger 24 (as explained in further detailbelow), the bevel gear assembly 84 a-c causes the secondary drive shaft82 to rotate, which in turn, because of the engagement of the drivegears 86, 88, causes the helical screw shaft 40 to rotate, which causesthe cutting instrument 34 to travel longitudinally along the channel 26to cut any tissue clamped within the end effector 16. The sled 36 may bemade of, for example, plastic, and may have a sloped distal surface. Asthe sled 36 traverses the channel 26, the sloped distal surface may camthe staple drivers 60 upward, which in turn push up or drive the staples62 in the staple cartridge 38 through the clamped tissue and against thestaple forming undersurface 66 of the anvil 28, thereby stapling thesevered tissue. When the cutting instrument 34 is retracted, the cuttinginstrument 34 and the sled 36 may become disengaged, thereby leaving thesled 36 at the distal end of the channel 26.

FIGS. 7-10 illustrate an exemplary embodiment of a motor-drivenendocutter, and in particular the handle 12 thereof, that providesoperator-feedback regarding the deployment and loading force of thecutting instrument 34 in the end effector 16. In addition, theembodiment may use power provided by the operator in retracting thefiring trigger 24 to power the device (a so-called “power assist” mode).As shown in the illustrated embodiment, the handle 12 includes exteriorlower side pieces 96, 98 and exterior upper side pieces 100, 102 thatfit together to form, in general, the exterior of the handle 12. Abattery 104 may be provided in the pistol grip portion 30 of the handle12. The battery 64 may be constructed according to any suitableconstruction or chemistry including, for example, a Li-ion chemistrysuch as LiCoO2 or LiNiO2, a Nickel Metal Hydride chemistry, etc. Thebattery 104 powers a motor 106 disposed in an upper portion of thepistol grip portion 30 of the handle 12. According to variousembodiments, the motor 106 may be a DC brushed driving motor having amaximum rotation of approximately 5000 to 100,000 RPM. The motor 106 maydrive a 90-degree bevel gear assembly 108 comprising a first bevel gear110 and a second bevel gear 112. The bevel gear assembly 108 may drive aplanetary gear assembly 114. The planetary gear assembly 114 may includea pinion gear 116 connected to a drive shaft 118. The pinion gear 116may drive a mating ring gear 120 that drives a helical gear drum 122 viaa drive shaft 124. A ring 126 may be threaded on the helical gear drum122. Thus, when the motor 106 rotates, the ring 126 is caused to travelalong the helical gear drum 122 by means of the interposed bevel gearassembly 108, planetary gear assembly 114 and ring gear 120.

The handle 12 may also include a run motor sensor 128 in communicationwith the firing trigger 24 to detect when the firing trigger 24 has beendrawn in (or “closed”) toward the pistol grip portion 30 of the handle12 by the operator to thereby actuate the cutting/stapling operation bythe end effector 16. The sensor 128 may be a proportional sensor suchas, for example, a rheostat or variable resistor. When the firingtrigger 24 is drawn in, the sensor 128 detects the movement, and sendsan electrical signal indicative of the voltage (or power) to be suppliedto the motor 106. When the sensor 128 is a variable resistor or thelike, the rotation of the motor 106 may be generally proportional to theamount of movement of the firing trigger 24. That is, if the operatoronly draws or closes the firing trigger 24 in a little bit, the rotationof the motor 106 is relatively low. When the firing trigger 24 is fullydrawn in (or in the fully closed position), the rotation of the motor106 is at its maximum. In other words, the harder the operator pulls onthe firing trigger 24, the more voltage is applied to the motor 106,causing a greater rate of rotation. In another embodiment, for example,a microcontroller (e.g., the microcontroller 250 of FIG. 29) may outputa PWM control signal to the motor 106 based on the input from the sensor128 in order to control the motor 106.

The handle 12 may include a middle handle piece 130 adjacent to theupper portion of the firing trigger 24. The handle 12 also may comprisea bias spring 132 connected between posts on the middle handle piece 130and the firing trigger 24. The bias spring 132 may bias the firingtrigger 24 to its fully open position. In that way, when the operatorreleases the firing trigger 24, the bias spring 132 will pull the firingtrigger 24 to its open position, thereby removing actuation of thesensor 128, thereby stopping rotation of the motor 106. Moreover, byvirtue of the bias spring 132, any time an operator closes the firingtrigger 24, the operator will experience resistance to the closingoperation, thereby providing the operator with feedback as to the amountof rotation exerted by the motor 106. Further, the operator could stopretracting the firing trigger 24 to thereby remove force from the sensor128, to thereby stop the motor 106. As such, the operator may stop thedeployment of the end effector 16, thereby providing a measure ofcontrol of the cutting/fastening operation to the operator.

The distal end of the helical gear drum 122 includes a distal driveshaft 134 that drives a ring gear 136, which mates with a pinion gear138. The pinion gear 138 is connected to the main drive shaft 80 of themain drive shaft assembly. In that way, rotation of the motor 106 causesthe main drive shaft assembly to rotate, which causes actuation of theend effector 16, as described above.

The ring 126 threaded on the helical gear drum 122 may include a post140 that is disposed within a slot 142 of a slotted arm 144. The slottedarm 144 has an opening 146 its opposite end 148 that receives a pivotpin 150 that is connected between the handle exterior side pieces 96,98. The pivot pin 150 is also disposed through an opening 152 in thefiring trigger 24 and an opening 154 in the middle handle piece 130.

In addition, the handle 12 may include a reverse motor (orend-of-stroke) sensor 156 and a stop motor (or beginning-of-stroke)sensor 158. In various embodiments, the reverse motor sensor 156 may bea normally-open limit switch located at the distal end of the helicalgear drum 122 such that the ring 126 threaded on the helical gear drum122 contacts and closes the reverse motor sensor 156 when the ring 126reaches the distal end of the helical gear drum 122. The reverse motorsensor 156, when closed, sends a signal to the motor 106 to reverse itsrotation direction, thereby retracting the cutting instrument 34 of theend effector 16 following a cutting operation.

The stop motor sensor 158 may be, for example, a normally-closed limitswitch. In various embodiments, it may be located at the proximate endof the helical gear drum 122 so that the ring 126 opens the switch 158when the ring 126 reaches the proximate end of the helical gear drum122.

In operation, when an operator of the instrument 10 pulls back thefiring trigger 24, the sensor 128 detects the deployment of the firingtrigger 24 and sends a signal to the motor 106 to cause forward rotationof the motor 106 at, for example, a rate proportional to how hard theoperator pulls back the firing trigger 24. The forward rotation of themotor 106 in turn causes the ring gear 120 at the distal end of theplanetary gear assembly 114 to rotate, thereby causing the helical geardrum 122 to rotate, causing the ring 126 threaded on the helical geardrum 122 to travel distally along the helical gear drum 122. Therotation of the helical gear drum 122 also drives the main drive shaftassembly as described above, which in turn causes deployment of thecutting instrument 34 in the end effector 16. That is, the cuttinginstrument 34 and sled 36 are caused to traverse the channel 26longitudinally, thereby cutting tissue clamped in the end effector 16.Also, the stapling operation of the end effector 16 is caused to happenin embodiments where a stapling-type end effector is used.

By the time the cutting/stapling operation of the end effector 16 iscomplete, the ring 126 on the helical gear drum 122 will have reachedthe distal end of the helical gear drum 122, thereby causing the reversemotor sensor 156 to be actuated, which sends a signal to the motor 106to cause the motor 106 to reverse its rotation. This in turn causes thecutting instrument 34 to retract, and also causes the ring 126 on thehelical gear drum 122 to move back to the proximate end of the helicalgear drum 122.

The middle handle piece 130 includes a backside shoulder 160 thatengages the slotted arm 144 as best shown in FIGS. 8 and 9. The middlehandle piece 130 also has a forward motion stop 162 that engages thefiring trigger 24. The movement of the slotted arm 144 is controlled, asexplained above, by rotation of the motor 106. When the slotted arm 144rotates CCW as the ring 126 travels from the proximate end of thehelical gear drum 122 to the distal end, the middle handle piece 130will be free to rotate CCW. Thus, as the operator draws in the firingtrigger 24, the firing trigger 24 will engage the forward motion stop162 of the middle handle piece 130, causing the middle handle piece 130to rotate CCW. Due to the backside shoulder 160 engaging the slotted arm144, however, the middle handle piece 130 will only be able to rotateCCW as far as the slotted arm 144 permits. In that way, if the motor 106should stop rotating for some reason, the slotted arm 144 will stoprotating, and the operator will not be able to further draw in thefiring trigger 24 because the middle handle piece 130 will not be freeto rotate CCW due to the slotted arm 144.

FIGS. 11 and 12 illustrate two states of a variable sensor that may beused as the run motor sensor 128 according to various embodiments of thepresent invention. The sensor 128 may include a face portion 164, afirst electrode (A) 166, a second electrode (B) 168, and a compressibledielectric material 170 (e.g., EAP) between the electrodes 166, 168. Thesensor 128 may be positioned such that the face portion 164 contacts thefiring trigger 24 when retracted. Accordingly, when the firing trigger24 is retracted, the dielectric material 170 is compressed, as shown inFIG. 12, such that the electrodes 166, 168 are closer together. Sincethe distance “b” between the electrodes 166, 168 is directly related tothe impedance between the electrodes 166, 168, the greater the distancethe more impedance, and the closer the distance the less impedance. Inthat way, the amount that the dielectric material 170 is compressed dueto retraction of the firing trigger 24 (denoted as force “F” in FIG. 12)is proportional to the impedance between the electrodes 166, 168, whichcan be used to proportionally control the motor 106.

Components of an exemplary closure system for closing (or clamping) theanvil 28 of the end effector 16 by retracting the closure trigger 22 arealso shown in FIGS. 7-10. In the illustrated embodiment, the closuresystem includes a yoke 172 connected to the closure trigger 22 by a pin174 that is inserted through aligned openings in both the closuretrigger 22 and the yoke 172. A pivot pin 176, about which the closuretrigger 22 pivots, is inserted through another opening in the closuretrigger 22 which is offset from where the pin 174 is inserted throughthe closure trigger 22. Thus, retraction of the closure trigger 22causes the upper part of the closure trigger 22, to which the yoke 172is attached via the pin 174, to rotate CCW. The distal end of the yoke172 is connected, via a pin 178, to a first closure bracket 180. Thefirst closure bracket 180 connects to a second closure bracket 182.Collectively, the closure brackets 180, 182 define an opening in whichthe proximal end of the proximate closure tube 72 (see FIG. 4) is seatedand held such that longitudinal movement of the closure brackets 180,182 causes longitudinal motion by the proximate closure tube 72. Theinstrument 10 also includes a closure rod 184 disposed inside theproximate closure tube 72. The closure rod 184 may include a window 186into which a post 188 on one of the handle exterior pieces, such asexterior lower side piece 96 in the illustrated embodiment, is disposedto fixedly connect the closure rod 184 to the handle 12. In that way,the proximate closure tube 72 is capable of moving longitudinallyrelative to the closure rod 184. The closure rod 184 may also include adistal collar 190 that fits into a cavity 192 in proximate spine tube 79and is retained therein by a cap 194 (see FIG. 4).

In operation, when the yoke 172 rotates due to retraction of the closuretrigger 22, the closure brackets 180, 182 cause the proximate closuretube 72 to move distally (i.e., away from the handle 12 of theinstrument 10), which causes the distal closure tube 74 to movedistally, which causes the anvil 28 to rotate about the pivot point 42into the clamped or closed position. When the closure trigger 22 isunlocked from the locked position, the proximate closure tube 72 iscaused to slide proximally, which causes the distal closure tube 74 toslide proximally, which, by virtue of the tab 44 being inserted in theopening 78 of the distal closure tube 74, causes the anvil 28 to pivotabout the pivot point 42 into the open or unclamped position. In thatway, by retracting and locking the closure trigger 22, an operator mayclamp tissue between the anvil 28 and channel 26, and may unclamp thetissue following the cutting/stapling operation by unlocking the closuretrigger 22 from the locked position.

According to various embodiments, the instrument 10 may include aninterlock for preventing instrument 10 operation when the staplecartridge 38 is not installed in the channel 26, or when the staplecartridge 38 is installed in the channel 26 but spent. Operation of theinterlock is twofold. First, in the absence of an unspent staplecartridge 38 within the channel 26, the interlock operates tomechanically block distal advancement of the cutting instrument 34through the channel 26 in response to actuation of the firing trigger24. Using suitable electronics disposed within the handle 12, theinterlock next detects the increase in current through the motor 106resulting from the immobilized cutting instrument 34 and consequentlyinterrupts current to the motor 106. Advantageously, the interlockeliminates the need for electronic sensors in the end effector 16, thussimplifying instrument design. Moreover, because the magnitude andduration of mechanical blocking force needed to produce the detectedincrease in motor current is significantly less than that which would beexerted if only a conventional mechanical interlock was used, physicalstresses experienced by instrument components are reduced.

According to various embodiments, the interlock may include (1) ablocking mechanism to prevent actuation of the cutting instrument 34 bythe motor 106 when an unspent staple cartridge 38 is not installed inthe channel 26, and (2) a lockout circuit to detect the current throughthe motor 106 and to interrupt the current through the motor 106 basedon the sensed current.

FIG. 31 is a flow diagram of the process implemented by the interlockaccording to various embodiments. At step 264, the actuation of thecutting instrument 34 by the motor 106 is mechanically blocked by theblocking mechanism in the absence of an unspent staple cartridge 38within the channel 26. As discussed below, the blocking mechanism mayinclude components or features of conventional mechanical interlocks.

At step 266, the current through the motor 106 resulting from theblocked actuation of the cutting instrument 34 is detected by thelockout circuit. As discussed below, detection of the current mayinclude, for example, the steps of sensing the motor current, generatinga signal representative of the sensed motor current, and comparing thegenerated signal to a threshold signal.

At step 268, the current through the motor 106 is interrupted based onthe detected current. Interrupting the current may include, for example,interrupting the current when the result of the comparison at step 266indicates that the generated signal exceeds the threshold signal.Interrupting the current through the motor 106 may further includeinterrupting the current based on a position of the cutting instrument34.

According to various embodiments, the blocking mechanism of theinterlock may include features similar or identical to those ofconventional mechanical interlocks for physically blocking advancementof the cutting instrument 34 in the absence of an unspent staplecartridge 38 within the channel 26. FIG. 13 illustrates a blockingmechanism 196 according to one embodiment. The blocking mechanism 196 isdisclosed in U.S. Pat. No. 7,044,352 entitled SURGICAL STAPLINGINSTRUMENT HAVING A SINGLE LOCKOUT MECHANISM FOR PREVENTION OF FIRING,which issued on May 16, 2006, which is incorporated herein by reference.As shown, the blocking mechanism 196 may comprise a pair of springfingers 198 positioned in the channel 26. In particular, the springfingers 196 may raise up to block the middle pins 50 of the cuttinginstrument 34 when the sled 36 (not shown in FIG. 13) is not present inan unfired position at the proximal end of the channel 26, such as whenthe staple cartridge 38 is not installed or when the staple cartridge 38is installed but spent. Although two spring fingers 198 are shown, itwill be appreciated that more or fewer spring fingers 198 may be usedinstead.

FIGS. 14-17 depict the operation of the spring fingers 198 sequentiallyas the instrument 10 is fired. In FIG. 14, an unspent staple cartridge38 has been inserted into the channel 26. The presence of the sled 36 inits unfired position depresses the spring fingers 198 such that thefiring drive slot 200 through which the middle pins 50 will pass isunimpeded.

In FIG. 15, firing of the staple cartridge 38 has commenced, with thesled 36 and the middle pins 50 of the cutting instrument 34 havingdistally traversed off of the spring fingers 198, which then spring upinto the firing drive slot 200.

In FIG. 16, the staple cartridge 38 is now spent with the sled 36 fullydriven distally and no longer depicted. The cutting instrument 34 isbeing retracted proximally. Since the spring fingers 198 pivot from amore distal point, the middle pins 50 of the cutting instrument 34 areable to ride up onto the spring fingers 198 during retraction, causingthem to be depressed out of the firing drive slot 200.

In FIG. 17, the cutting instrument 34 is fully retracted and nowconfronts the non-depressed pair of spring fingers 198 to prevent distalmovement. The blocking mechanism 196 thereby remains activated until anunspent staple cartridge 38 is installed in the channel 26.

FIG. 18 depicts a blocking mechanism 202 according to anotherembodiment. The blocking mechanism 202, which is disclosed in U.S. Pat.No. 7,044,352 referenced above, includes a pair of hooks 204 havingramped ends 206 distally placed with regard to attachment devices 208.The attachment devices 208 are inserted through apertures 210 in thechannel 26, thereby springedly attaching the hooks 204 to the channel26. The ramped ends 206 lie above a hook recess 212 defined in thechannel 26. Thus, when each ramped end 206 is contacted by the sled 36of an unspent staple cartridge 38 (not shown in FIG. 18), the rampedends 206 are depressed into the hook recess 212, thereby clearing theway for the middle pins 50 of the cutting instrument 34 to move distallythrough the firing drive slot 200 so that the staple cartridge 38 may beactuated. A thin shaft 214 coupling the attachment devices 208respectively to the ramped end 206 of each hook 204 resiliently respondsto absence of the sled 36, as depicted, wherein the ramped ends 206return to impede the firing drive slot 200 to block the retracted middlepins 50 of the cutting instrument 34. Although two hooks 204 are shown,it will be appreciated that more or fewer hooks 204 may be used instead.

FIGS. 19-22 depict the sequence of operation of the hooks 204. In FIG.19, the staple cartridge 38 is unspent so that the distally positionedsled 36 depresses the ramped ends 206 into the hook recess 212, allowingthe middle pins 50 of the cutting instrument 34 to move distally throughthe firing drive slot 200 during firing, as depicted in FIG. 20. Withthe sled 36 and middle pins 50 distally removed with respect to theblocking mechanism 202, the ramped ends 206 resiliently raise out of thehook recess 212 to occupy the firing drive slot 200.

In FIG. 21, the cutting instrument 34 is being retracted to the point ofcontacting the ramped ends 206 of the hooks 204. Since the distal end ofthe ramped ends 206 is lower than the proximal part of the ramped ends206, the middle pins 50 of the cutting instrument 34 ride over theramped ends 206, forcing them down into the hook recess 212 until themiddle pins 50 are past the ramped ends 206, as depicted in FIG. 22,wherein the ramped ends 206 resiliently spring back up to block themiddle pins 50. Thus, the cutting instrument 34 is prevented from distalmovement until an unspent staple cartridge 38 is installed in thechannel 26.

FIG. 23 depicts a blocking mechanism 216 according to yet anotherembodiment. The blocking mechanism 216 is disclosed in U.S. Pat. No.6,988,649 entitled SURGICAL STAPLING INSTRUMENT HAVING A SPENT CARTRIDGELOCKOUT, which issued on Jan. 24, 2006, which is incorporated herein byreference. The blocking mechanism 216 is integrally formed with thestaple cartridge 38 and includes proximally projecting blocking members218 resiliently positioned above the sled 36 (not shown in FIG. 23). Inparticular, the blocking members 218 each reside within a downward andproximally opening cavity 220. Each blocking member 218 includes a leafspring end 222 that is held within the cavity 220.

The cavities 220 are vertically aligned and spaced and parallel about aproximally presented vertical slot 224 in the staple cartridge 38through which the cutting surface 56 (not shown in FIG. 23) passes. Thestaple cartridge 38 also includes slots 226 that longitudinally passthrough the staple cartridge 38, being open from a portion of a proximaland underside of the staple cartridge 38 to receive the sled 36.

Each blocking member 218 has a deflectable end 228 having a rampeddistal side 227 and blocking proximal side 229. The blocking members 218are shaped to reside within their respective cavities 220 when depressedand to impede the distally moving middle pins 50 of the cuttinginstrument 34 when released.

FIGS. 24-27 depict the blocking mechanism 216 sequentially as theinstrument 10 is fired. In FIG. 24, an unspent staple cartridge 38 hasbeen inserted into the channel 26 with the sled 36 depressing upward thedeflectable ends 228 so that the firing drive slot 200 is unimpeded.

In FIG. 25, firing of the staple cartridge 38 has commenced, with thesled 36 and the middle pins 50 of the cutting instrument 34 havingdistally traversed past the deflectable ends 228, which then spring downinto the firing drive slot 200.

In FIG. 26, the staple cartridge 38 is now spent with the sled 36 fullydriven distally and no longer depicted. The cutting instrument 34 isbeing retracted proximally. Since the deflectable ends 228 pivot from amore distal point, the middle pins 50 of the cutting instrument 34 areable to ride under the ramped distal sides 227 of the deflectable ends228 during retraction, causing them to be depressed up, out of thefiring drive slot 200.

In FIG. 27, the cutting instrument 34 is fully retracted and the middlepints 50 now confront the blocking proximal sides 229 of thenon-depressed (released) pair of deflectable ends 228 to prevent distalmovement. The blocking mechanism 216 thereby remains activated until anunspent staple cartridge 38 is installed in the channel 26.

The blocking mechanisms 196, 202, 216 of the above-discussed embodimentsare provided by way of example only. It will be appreciated that othersuitable blocking mechanisms, such as blocking mechanisms disclosed inpending U.S. patent application Ser. No. 11/266,961 entitled LOCKOUTMECHANISMS AND SURGICAL INSTRUMENTS INCLUDING SAME, which issued as U.S.Pat. No. 7,328,828 on Feb. 12, 2008, which is incorporated herein byreference, may be used instead.

FIG. 28 is a schematic diagram of an electrical circuit 231 of theinstrument 10 according to various embodiments of the present invention.In certain embodiments, the circuit 231 may be housed within the handle12. In addition to the sensor 128, sensors 156, 158 (depicted as anormally-open limit switch and a normally-closed limit switch,respectively), the battery 104, and the motor 106, the circuit 231 mayinclude a single-pole double-throw relay 230, a single-pole single-throwrelay 232, a double-pole double-throw relay 234, a current sensor 236, aposition sensor 238, and a current detection module 240. Relay 232, thecurrent sensor 236, the position sensor 238, and the current detectionmodule 240 collectively form a lockout circuit 241. As described below,the lockout circuit 241 operates to sense the current through the motor106 and to interrupt the current based upon the sensed current, thus“locking out” the instrument 10 by disabling its operation.

As described above, sensor 128 is activated when an operator pulls inthe firing trigger 24 after locking the closure trigger 22. When switch156 is open (indicating that the cutting/stapling operation of the endeffector 16 is not yet complete), coil 242 of relay 230 is de-energized,thus forming a conductive path between the battery 104 and relay 232 viaa normally-closed contact of relay 230. Coil 244 of relay 232 iscontrolled by the current detection module 240 and the position sensor238 as described below. When coil 244 is de-energized and coil 242 isde-energized, a conductive path between the battery 104 and anormally-closed contact of relay 234 is formed. Relay 234 controls therotational direction of the motor 106 based on the states of switches156, 158. When switch 156 is open and switch 158 is closed (indicatingthat the cutting instrument 34 has not yet fully deployed distally),coil 246 of relay 234 is de-energized. Accordingly, when coils 242, 244,246 are collectively de-energized, current from the battery 104 flowsthrough the motor 106 via the normally-closed contacts of relay 234 andcauses the forward rotation of the motor 106, which in turn causesdistal deployment of the cutting instrument 34 as described above.

When switch 156 is closed (indicating that the cutting instrument 34 hasfully deployed distally), coil 242 of relay 230 is energized, and coil246 of relay 234 is energized via a normally-open contact of relay 230.Accordingly, current now flows to the motor 106 via normally-opencontacts of relays 230, 234, thus causing reverse rotation of the motor106 which in turn causes the cutting instrument 34 to retract from itsdistal position and switch 156 to open. Coil 242 of relay 230 remainsenergized until limit switch 158 is opened, indicating the completeretraction of the cutting instrument 34.

The magnitude of current through the motor 106 during its forwardrotation is indicative of forces exerted upon the cutting instrument 34during its deployment. As described above, the absence of an unspentstaple cartridge 38 in the channel 26 (e.g., the presence of a spentstaple cartridge 38 or the absence of a staple cartridge 38 altogether)results in activation of the blocking mechanism 196, 202, 216 such thatdistal movement of the cutting instrument 34 is prevented. The resistiveforce exerted by the blocking mechanism 196, 202, 216 against thecutting instrument 34 causes an increase in motor torque, thus causingmotor current to increase to a level that is measurably greater thanthat present during a cutting and stapling operation. Accordingly, bysensing the current through the motor 106, the lockout circuit 241 maydifferentiate between deployment of the cutting instrument 34 when anunspent cartridge 38 is installed in the channel 26 versus deployment ofthe cutting instrument 34 when an unspent cartridge 38 is absent fromthe channel 26.

The current sensor 236 may be coupled to a path of the circuit 231 thatconducts current to the motor 106 during its forward rotation. Thecurrent sensor 236 may be any current sensing device (e.g., a shuntresistor, a Hall effect current transducer, etc.) suitable forgenerating a signal (e.g., a voltage signal) representative of sensedmotor current. The generated signal may be input to the currentdetection module 240 for processing therein, as described below.

According to various embodiments, the current detection module 240 maybe configured for comparing the signal generated by the current sensor236 to a threshold signal (e.g., a threshold voltage signal) todetermine if the blocking mechanism 196, 202, 216 has been activated.For a given instrument 10, a suitable value of the threshold signal maybe empirically determined a priori by, for example, measuring the peaksignal generated by the current sensor 236 when the cutting instrument34 is initially deployed (e.g., over the first 0.06 inches of its distalmovement) during a cutting and stapling operation, and when the cuttinginstrument 34 is deployed and encounters the activated blockingmechanism 196, 202, 216. The threshold signal value may be selected tobe less than the peak signal measured when the blocking mechanism 196,202, 216 is activated, but larger than the peak signal measured during acutting and stapling operation.

In certain embodiments and as shown in FIG. 28, the current detectionmodule 240 may comprise a comparator circuit 248 for receiving thethreshold and current sensor 236 signals and generating a discreteoutput based on a comparison of the received signals. For example, thecomparator circuit 248 may generate a 5 VDC output when the thresholdsignal is exceeded and a 0 VDC output when the threshold signal is notexceeded. The threshold signal may be generated, for example, using asuitable signal reference circuit (e.g., a voltage reference circuit)(not shown). The design and operation of the comparator circuit 248 andsignal reference circuit are well known in the art and are not describedfurther herein.

The result of the threshold and current sensor 236 signal comparison isprimarily of interest during the initial deployment (e.g., during thefirst 0.06 inches of distal movement) of the cutting instrument 34.Accordingly, the current detection module 240 may limit the comparisonbased on the distal position of the cutting instrument 34 as indicatedby the position sensor 238. The position sensor 238 may be any type ofposition sensing device suitable for generating a signal indicative of adistal position of the cutting instrument 34. In one embodiment and asshown in FIG. 28, for example, the position sensor 238 may be anormally-open Hall effect position switch 238 that is actuated based onits proximity to a magnet mounted on the ring 126. The position switch238 may mounted within the handle 12 and operate such that when thedistal position of the cutting instrument 34 (as indicated by theposition of ring 126) is within a pre-determined distance (e.g., distalposition <0.06 inches) of its proximal-most position, the positionswitch 238 is closed. Conversely, when the distal position of thecutting instrument 34 exceeds the predetermined distance (e.g., distalposition >0.06 inches), the position switch 238 is opened. The positionswitch 238 may be connected in series with the output of the comparatorcircuit 248 to limit the comparison based on the position of the cuttinginstrument 34. In this way, if the threshold signal is exceeded when thedistal position of the cutting instrument 34 is greater thanpre-determined distance, the output of the position switch 238 willremain at 0 VDC (according to the example presented above), regardlessof the result of the comparison. It will be appreciated that other typesof position sensors 238 (e.g., mechanically-actuated limit switches,rotary potentiometers, etc.) may be used instead as an alternative tothe Hall effect position switch 238 described above. Additionally, itwill be appreciated that auxiliary contacts (not shown) of switch 158may be used as an alternative to a separate position sensor 238. Inembodiments in which the position sensor 238 does not include a switchedoutput (e.g., when the position sensor 238 is a potentiometer or otheranalog-based position sensor), additional processing of the positionsensor 236 output using, for example, a second comparator circuit, maybe necessary.

As shown in FIG. 28, the output of the position switch 238 may beconnected to coil 244 of relay 232. Driver circuitry (not shown) betweenthe position switch 238 and the coil 244 may be provided if necessary.Accordingly, if the signal generated by the current sensor 236 exceedsthe threshold signal (indicating activation of the blocking mechanism196, 202, 216 due to the absence of an unspent staple cartridge 38), andthe cutting instrument 34 is within the predetermined distance of itsproximal-most position, coil 244 will be energized. This causesnormally-closed switch of relay 232 to open, thereby interruptingcurrent flow to the motor 106 and removing the resistive force exertedby the blocking mechanism 196, 202, 216 upon the cutting instrument 34.Importantly, because the blocking mechanism 196, 202, 216 need onlyapply a mechanical blocking force sufficient to cause the thresholdsignal to be exceeded, the physical stresses exerted by the blockingmechanism 196, 202, 216 are reduced in magnitude and duration comparedto those that would be exerted if only conventional mechanicalinterlocks were used. Furthermore, because the interlock does notrequire electronic sensors in the end effector 16, instrument design issimplified.

FIG. 29 is a schematic diagram of an electrical circuit 249 of theinstrument 10 according to another other embodiment of the presentinvention in which a processor-based microcontroller 250 is used toimplement functionality of the lockout circuit 241 described above.Although not shown for purposes of clarity, the microcontroller 250 mayinclude components well known in the microcontroller art such as, forexample, a processor, a random access memory (RAM) unit, an erasableprogrammable read-only memory (EPROM) unit, an interrupt controllerunit, timer units, analog-to-digital conversion (ADC) anddigital-to-analog conversion (DAC) units, and a number of generalinput/output (I/O) ports for receiving and transmitting digital andanalog signals. The current sensor 236 and the position sensor 238 maybe connected to analog and digital inputs, respectively, of themicrocontroller 250, and the coil 244 of relay 232 may be connected to adigital output of the microcontroller 250. It will be appreciated thatin embodiments in which the output of the position sensor 238 is ananalog signal, the position sensor 238 may be connected to an analoginput instead. Additionally, although the circuit 249 of FIG. 29includes relays 230, 232, 234, it will be appreciated that in otherembodiments the relay switching functionality may be replicated usingsolid state switching devices, software, and combinations thereof. Incertain embodiments, for example, instructions stored and executed inthe microcontroller 250 may be used to control solid state switchedoutputs of the microcontroller 250. In such embodiments, switches 156,158 may be connected to digital inputs of the microcontroller 250.

FIG. 30 is a flow diagram of a process implemented by themicrocontroller 250 according to various embodiments. At step 252, themicrocontroller 250 receives the signal generated by the current sensor236 via an analog input and converts the received signal into acorresponding digital current sensor signal.

At step 254, values of the digital current sensor signal are compared toa digital threshold value stored within the microcontroller 250. Thedigital threshold value may be, for example, a digitized representationof the threshold signal discussed above in connection with FIG. 28. Ifall values of the digital current sensor signal are less than thedigital threshold value, the process terminates at step 256. If a valueof the digital current sensor signal exceeds the digital thresholdvalue, the process proceeds to step 258.

At step 258, the position sensor 238 input is processed to determine ifthe cutting instrument 34 is within the predetermined distance of itsproximal-most position. If the cutting instrument 34 is not within thepredetermined distance, the process is terminates at step 260. If thecutting instrument 34 is within the predetermined distance, the processproceeds to step 262.

At step 262, the digital output to corresponding to coil 244 isenergized, thus causing the normally closed contacts of relay 232 toopen, which in turn interrupts the current flow to the motor 106.

Although embodiments described above compare the magnitude of thecurrent sensor signal (or a digitized version thereof) to a thresholdsignal or value, it will be appreciated that other metrics for analyzingthe current sensor signal may additionally or alternatively be used todifferentiate between deployment of the cutting instrument 34 when anunspent cartridge 38 is installed in the channel 26 versus deployment ofthe cutting instrument 34 when an unspent cartridge 38 is absent fromthe channel 26. For example, the current detection module 240 or themicrocontroller 250 may be configured to determine derivative and/orintegral characteristics of the current sensor signal for comparison tocorresponding thresholds signals or values. Additionally, in certainembodiments the current sensor signal may be processed prior to itsanalysis using, for example, signal conditioners and/or filtersimplementing one or more filter response functions (e.g., infiniteimpulse response functions).

The various embodiments of the present invention have been describedabove in connection with cutting-type surgical instruments. It should benoted, however, that in other embodiments, the inventive surgicalinstrument disclosed herein need not be a cutting-type surgicalinstrument. For example, it could be a non-cutting endoscopicinstrument, a grasper, a stapler, a clip applier, an access device, adrug/gene therapy delivery device, an energy device using ultrasound,RF, laser, etc.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, the device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

Although the present invention has been described herein in connectionwith certain disclosed embodiments, many modifications and variations tothose embodiments may be implemented. For example, different types ofend effectors may be employed. Also, where materials are disclosed forcertain components, other materials may be used. The foregoingdescription and following claims are intended to cover all suchmodification and variations.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdoes not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

What is claimed is:
 1. A robotic surgical system, comprising: a surgicalrobot; a surgical instrument, comprising: an end effector, comprising:an anvil; a channel; and a cartridge configured to be replaceablypositioned in said channel; a firing assembly, comprising: a firingmember movable from an unfired position to a fired position during afiring stroke; and a sled movable from a proximal position to a distalposition as said firing member is moved through said firing stroke; anda lockout mechanism configured to prevent said firing stroke when saidsled is not in said proximal position; a motor comprising a rotatableoutput, wherein said rotatable output is operably coupled with saidfiring member, and wherein said motor is couplable with a supply ofcurrent; and a current sensor configured to detect the current throughsaid motor, wherein when said current through said motor exceeds athreshold value said firing member is prevented from completing saidfiring stroke, wherein said threshold value corresponds to said currentthrough said motor when said lockout mechanism is activated, and whereinsaid motor is de-energized when said current through said motor exceedssaid threshold value.
 2. A robotic surgical system, comprising: asurgical instrument, comprising: an end effector, comprising: an anviljaw; a staple cartridge jaw comprising a channel; and a staple cartridgeconfigured to be releasably positioned within said channel; a firingassembly, comprising: a firing member movable from an unfired positionto a fired position during a firing stroke; and a sled movable from aproximal position to a distal position; and a lockout mechanismconfigured to prevent said firing stroke when said sled is not in saidproximal position; a motor comprising a rotatable output, wherein saidrotatable output is operably coupled with said firing member, whereinsaid rotatable output is configured to move said firing member betweensaid unfired position and said fired position, and wherein said motor iscouplable with a supply of current; and a sensing system configured todetect the current through said motor, wherein said firing member isprevented from continuing said firing stroke when said current throughsaid motor exceeds a threshold value, wherein said current through saidmotor exceeding said threshold value is indicative of said lockoutmechanism being activated, and wherein said motor is de-energized whensaid current through said motor exceeds said threshold value.
 3. Arobotic surgical system, comprising: a surgical robot; a surgicalinstrument, comprising: an end effector, comprising: a longitudinallyextending channel; an anvil pivotally attached to said channel; and astaple cartridge replaceably positioned in said channel; a firingassembly, comprising: a firing member movable from an unfired positionto a fired position during a firing stroke; and a sled movable from aproximal position to a distal position as said firing member is movedthrough said firing stroke; and a lockout mechanism configured toprevent said firing stroke when said sled is not in said proximalposition; a motor comprising a rotatable output, wherein said rotatableoutput is operably coupled with said firing member, and wherein saidmotor is configured to be coupled with a supply of current; and alockout circuit configured to sense the current through said motor andprevent the completion of said firing stroke when said current throughsaid motor exceeds a threshold value, wherein said threshold valuecorresponds to said current through said motor when said sled is not insaid proximal position, and wherein said motor is de-energized when saidcurrent through said motor exceeds said threshold value.